Introduction Motordetal-Konotop Cylinder liner manufacturing plant We know everything about cylinder liners 1
Company Motordetal-Konotop is the largest Total area – 20,2012 hectares fully integrated company in the Building area – 72,609 square meters CIS specializing in cylinder liner Production buildings total area – production 68,795 square meters 2
Company We use centrifugal casting method, induction melting from special wear-resistant cast iron. Flexible production based upon highly adaptive manufacturing lines and cells. We have well mastered a wide range of cylinder liners and sleeves for automotive, tractor, vessel, locomotive and stationary applications. We conduct high-precision finish machining of cylinder liners using CNC turning and honing machines. 3
Company Technology: high-precision equipment, including casting carrousels, plateau honing, heat treatment, phosphatization of cylinder liners, induction hardening and plasma anticavitation of cylinder liners. Use of state-of-the-art equipment combined with experienced and well- trained personnel makes it possible to reach high levels of product quality and protect the environment. 4
Company Date of establishment: Motordetal-Konotop was established on the basis of the former national enterprise, whose activity started in 1943. Production: Main production technology – special gray iron casting. 100% of castings are produced by centrifugal casting method. The minimum casting weight is 8 kg, the maximum casting weight is 400 kg. Casting inner diameters range from 50 to 350 mm. Casting length is from 250 to 1110 mm. Manufacturing capacity: 56 200 tons of usable castings 4,63 million liners and sleeves per year 5
Foundry Melting Casting Capacities 6
Melting (1) Two-crucible medium frequency induction melting furnace Junker 2MFTGe 4000 (Germany). Crucible capacity – 4 tons. (5) Commercial frequency induction crucible furnaces ИЧТ -10. Crucible capacity – 10 tons. (3) Commercial frequency induction crucible furnaces ИЧТ -2,5. Crucible capacity – 2.5 tons. Total production capacity – 5 270 tons per month. 7
Casting Centrifugal casting process is used to produce cylinder lining tubes. (1) Eleven-station rotary-hearth machine ККМ - 11Л – 60 000 castings per month. (3) Eight-station rotary-hearth machines ККУ – 105 000 castings per month. (31) Single- station rotary machines РЛМ - 260. Production capacity – 99 000 castings per month. (2) Single- station rotary machines РЛМ - 460. Production capacity – 500 large- bore cylinder liner castings per month. Total production capacity – 264 500 castings per month. 8
Machining Machining cells Phosphatization line Induction hardening & heat treatment cell 9
Machining (10) Cylinder liner finishing cells, Production capacity – 281 800 cylinder liners per month. O.D. finishing – CNC turning machines Gildemeister CTX-400E, Takisawa TC-350L10, Bevers 1П420ПФ40, 16А20Ф3. I.D. finishing – CNC honing machines Gehring Z-NC-600- 125, Nagel VS 10-60 RA, Nagel 2 VS10-80T, 3K83. 10
Machining (3) Rough machining and semi- finished cylinder liner manufacturing areas equipped with local-made specialized semi-automatic machine- tools. Combined production capacity – 98 000 semi-finished cylinder liners per month. Marine and locomotive cylinder liner machining area. Production capacity – 6 000 cylinder liners per month. Equipment: MaxMiller MD5S, EMCO Hyperturn 690MCPlus, PT755, 1740F3 11
Production of cast-in cylinder liners Currently we are in process of installing the Gibson foundry complex for the production of tube castings with the length of 2 m. The estimated capacity is 2 million pieces of rough cast-in and dry liners for aluminum blocs annually. We actually supply the cast-in and dry liners both to build and aftermarket in number of about 500K pieces per year. 12
Table of main materials To produce the cylinder liners more than 140 material types are used depending on customer’s specifications. No. Material Hardness, Tensile Description Application НВ specification strength, MPa МС 05.007 -1 С r, Cu alloyed pearlitic cast iron 1 217-269 210 Wet liners for passenger and light commercial vehicles engines МС 01.001 - С r, Cu alloyed pearlitic cast iron 2 230-290 250 Dry cylinder liners engines 5.1Р МС 01.001 - 3 217-269 250 Cr, Ni, Cu alloyed pearlitic cast iron Cast-in liners for aluminum blocs 9.8 М C 04.006-4 4 217-277 250 Pearlitic cast iron with low Truck and agricultural machinery phosphorus content for induction engines hardening up to 42-52HRc МС 02.007 С r, Mo, B alloyed wear- resistant 5 230-280 250 Truck engine pearlitic cast iron МС 01.001 6 230-277 260 Cr alloyed pearlitic cast iron with Truck and light commercial average phosphorus content vehicle engines МС 01.001 -1 7 230-285 260 Cr alloyed pearlitic cast iron with Trucks engines high phosphorus content МС 02.003 8 230-270 280 Cr, Mo alloyed pearlitic cast iron Heavy duty truck engines МС 07.008 9 250-310 330 Cu, Cr, Mo alloyed pearlitic cast iron High loaded truck and locomotive engines МС 04.006 -6 10 270-330 380 Pearlitic cast iron with high tensile High loaded truck engines strength МС 0 2.011 11 230-300 320 Bainitic cast iron High loaded truck engines 13 МС 07.005 12 270-330 400 Bainitic cast iron High loaded truck and locomotive engines
Microstructure Typical microstructure on the working surface of cylinder liner Graphite per ISO 945: predominantly type A, Matrix: fine pearlite, ferrite up to 2% В is allowed. Size 4-6, size 7 is allowed. Steadite: continuous network Steadite: broken network Steadite: isolated inclusions 14
Quality assurance Our test lab equipment: Spectrolab spectrometers, CS- 200gas analyzer, Wolpert 971/3000, hardness meters, Tira 4000 tensile testing machine, sample preparation system, Olympus microscopes, IA-32 structure analyzer. Central plant lab equipment: Mahr Perthometer Concept and S8P profilometers, a Carl Zeiss microscope, optical calipers. Operational control and final acceptance equipment: 100% finish control of main air/electronic instruments, Mahr cylinder liner parameters to ensure М2 and М4 profilometers, special product quality. fixtures and measurement tools. 15
Material inspection 16
Material inspection 17
Dimensional control 18
Quality assurance 19
Customers’ awards & recognition Motordetal-Konotop was honored as best supplier to MTU Friedrichshafen, Germany in 2014. Motordetal-Konotop also got recognition from Perkins Engines Company, United Kingdom in 2012-2014 for its exemplary year-to-year performance in the supply of dry cylinder liners. 20
Main OEM customers 21
Main Aftermarket customers 22
Advantages Single specialization and focus on production of cylinder liners Proximity to Western Europe, short order lead time Fully integrated production: from production of castings to complete machining and all-round quality control Highly skilled and motivated personnel Access to local low cost raw materials and human resources Timely delivery, production reserve capacity Well developed customer communication practices, European culture and mentality of plant personnel Certified quality assurance systems, environmental, health & safety management, health in conformity with international standards 23
Experiences Almost a 50-year cylinder liner manufacturing tradition and experience Stable quality and recognitions from the customers 80% of liner destined for truck applications 1 500 part numbers mastered ranging from 60 to 350 mm bore 140 material specifications developed including special materials with ultimate properties (pearlitic cast iron with high tensile, bainitic, etc) Modern production technologies (centrifugal casting, CNC machining, plateau & slide honing capabilities, roller burnishing, statistic control and tracebility) Supply of European OEM andall Russian & Ukrainian engines plants Strategical partnership with Kolbenschmidt 24
Strategy To maintain the role of the biggest manufacturer of cylinder liners in Eastern Europe Become a 1 st tier OEM supplier for truck and tractor application Ultimate customer satisfaction via the supply of high quality products, services and support Motivation and satisfaction of the staff Cost reduction initiatives to let customer become more competitive Adoption of zero defect philosophy Reasonable prices and affordable profit 25
Official North American Representative 26
Conclusion Many thanks for such an opportunity to present our company and your attention! 27
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